- no title specified

Risk Failure Mode and Effect Analysis (RFMEA)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (RISK FMEA)

Item

Potential Risk Responsibility

PFMEA Number

Product Name & Model

Key Date

Prepared by

Core Team

Date (Original)

Date (Revised)

Op Seq #

Process/ Product/ Function/ Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

Design Failure Mode and Effect Analysis (DFMEA)

Design FAILURE MODE AND EFFECTS ANALYSIS (PRODUCT FMEA)

Item

Design Responsibility

DFMEA Number

Product Name & Model

Key Date

Prepared by

Core Team

Date (Original)

Date (Revised)

Op Seq #

Design Part/ Product /Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

Process Failure Mode and Effect Analysis (PFMEA)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Item

Process Responsibility

PFMEA Number

Product Name & Model

Key Date

Prepared by

Core Team

Date (Original)

Date (Revised)

Op Seq #

Process Function/ Task/ Tool/ Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

System Failure Mode and Effect Analysis (SFMEA)

SYSTEM FAILURE MODE AND EFFECTS ANALYSIS (SYSTEM FMEA)

Item

System Responsibility

SFMEA Number

Product Name & Model

Key Date

Prepared by

Core Team

Date (Original)

Date (Revised)

Op Seq #

System Architecture/ Execution/ Function/ Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

Software Failure Mode and Effect Analysis (SWFMEA)

SOFTWARE FAILURE MODE AND EFFECTS ANALYSIS (SOFTWARE FMEA)

Item

Software Responsibility

SWFMEA Number

Product Name & Model

Key Date

Prepared by

Core Team

Date (Original)

Date (Revised)

Op Seq #

Software Architecture/ Algorithm/ Code/ Function/ Requirment

Script/Code Function ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

Operations Failure Mode and Effect Analysis (OFMEA)

OPERATIONS FAILURE MODE AND EFFECTS ANALYSIS (OPERATIONS FMEA)

Item

Operations Responsibility

OFMEA Number

Product Name & Model

Key Date

Prepared by

Core Team

Date (Original)

Date (Revised)

Op Seq #

Operation Function/ Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

Design Failure Mode and Effect Analysis (DFMEA)

(Design FMEA)

System :

Subsystem:

FMEA Version :

V0.1

Component :

Design Responsibility :

Page:

Model Year (s)/ Program(s) :

Prepared by:

Core Team :

Key Date :

FMEA Date (Orig.) :

Item / Function

Requirement

Potential Effect(s) of Failure

Severity

Potential Failure Mode

Characteristics

Classification

Potential Cause(s) of Failure

Current Design

RPN

Recommended Action

Responsibility & Target Completion Date

Action Results

Controls Prevention

Occurrence

Controls Detection

Detection

Actions Taken Completion Date

Severity

Occurrence

Detection

RPN

APPEARANCE APPROVAL REPORT

PART NUMBER

DRAWING NUMBER

APPLICATION

Aluminium part

PART NAME

BUYER CODE

E/C LEVEL

DATE

SUPPLIER NAME

MANUFACTURING ADDRESS

SUPPLIER CODE

LVL d.o.o.

LOCATION

REASON FOR

PART SUBMISSION WARRANT

SPECIAL SAMPLE

RE-SUBMISSION

OTHER

SUBMISSION

PRE TEXTURE

FIRST PRODUCTION SHIPMENT

ENGINEERING CHANGE

APPEARANCE EVALUATION

SUPPLIER SOURCING AND TEXTURE INFORMATION

PRE-TEXTURE

EVALUATION

CORRECT

AND PROCEED

CORRECT AND

RESUBMIT

APPROVED TO

TEXTURE

COLOR EVALUATION

COLOR SUFFIX

COLOR HEX

TRISTIMULUS DATA

DL*

Da*

Db*

DE*

CMC

MASTER NUMBER

MASTER DATE

MATERIAL TYPE

MATERIAL SOURCE

HUE

RED

YEL

GRN

BLU

VALUE

LIGHT

DARK

CHROMA

GRAY

CLEAN

GLOSS

HIGH

LOW

METALLIC BRILLIANCE

HIGH

LOW

COLOR SHIPPING SUFFIX

PART DISPOSITION

SUPPLIER SIGNATURE

PHONE NUMBER

DATE

CUSTOMER REPRESENTATIVE SIGNATURE

DATE

Control plan

Prcess Control Plan (PCP)

Prototype Pre-Launch Production

Control Plan Number

Key Contact& Phone

Date (Original)

Date (Revised)

Part Number/Latest change level

Core Team

Part Name/Description

Supplier/Plant approval date

Supplier/Plant

Supplier Code

Customer Quality Approval date (if required)

Op Seq #

Operation Description (Do this, to this, with this)

Machine Device/Jig/tools for manufacturing

Characteristics

Class

Methods

Reaction Plan

Product

Process

Prodcut/Process specification Tolerance

Evaluation Measurement technique

Sample

Control Methods

Size

Frequency

Advanced Product Quality Planning ( APQP) Process

Comment:

Date of Issue:

Form Number: 01

Supplier

Date

Location

Review #.

Supplier Code

Project

Risk Assessment

Part Name

New :

Part Number

Other Risks

User Plant (s)

[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'APQP Team Participants; Supplier, Sub-tier Suppliers, and BorgWarner Personnel, including all affected Plants.'
NOTE: '']

Team Members

Company/Title

Phone

e-mail

Build Level

Prototype

Required Date

Quantity

[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'Define the Number of Special Characteristics that may be customer specific including: '
NOTE: '• "Significant"'
NOTE: '• "Major"'
NOTE: '• "Critical"'
NOTE: '• "High Impact"'
NOTE: 'that requires on-going statistical capability and/or requires validation in the Process Control Plan.'
NOTE: '']

Special Characteristics

Comments

APQP Elements

GYR

[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'Status = Green, Yellow or Red as defined in definitions tab.'
NOTE: ''
NOTE: '']

Program

Supplier

Closed

Champion

[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'The current revision & date for the applicable document '
NOTE: '']

Document

[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'Contingency plans are required for any element that has a yellow or red status.'
NOTE: '']

Remarks

TIMELINE

Status

Need

Timing

Date

Name

Revision

Date

Date & Rev.

Phase 1.0 : Kick-off & Planning

1) Project team established

2) Specification and system review

3) Project plan review

- Preliminary Capacity study

- Preliminary sub-supplier plan

- Preliminary Traceability tree with BoM.

- Process Equipment / Control equip/ Prod. gauges

- Prototype Tooling (with specification release date)

- Production Tooling (with specification release date)

4) Feasibility

5) PPAP level agreed

Phase 2.0 : Process & Design Development

1) Process flow chart

- Floor plan layout

2 Process-FMEA

- Process Equipment / Control equip / Prod. gauges

- Important characteristics defined and agreed

3) Measurement System Plan

- Meassurement system analysis plan

- Preliminary Process Capability Study Plan

4 Prelimnary Control Plan

5) Process Instructions

- tooling maintenance management plan

- machine maintenance plan

- employee skill maintenance plan

6) Packaging Evaluation

Phase 3.0 : Product & Process Validation

1) Control Plan

- work instructions

2) PPAP

3) Production Trial Run

- Run at Rate for capacity

- Measurement System Evaluation

- Process Capability Study

4) Production Part Approval (PPAP)

- PSW / I.S.I.R

- PPAP Sign Off

Phase 4.0 : Confirmation of tools & production

- Trial casting successfully validated

- EMPB confirmed

- PSW confirmed

- Open Actions list reviewed and closed

- Close APQP

- Open Continuous Imrpovement Plan (if remaining issues)

Open Issues - Action Plans

APQP Element

Date

Description of Concern

Actions Taken / Implemented

Responsible

Completion Date

[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'Open / Closed'
NOTE: '']

Status

Meeting Log
			Date of APQP Meetings
Name of Participant	Topic	Kick-off	1	2	3	4	5	6	7	8	9

Risk/Status Assessment

Risk

Color

Definition

High

Red

Target dates and/or deliverables are at risk. A recovery work plan is not available and/or implemented, or the work plan does not achieve program targets.

Moderate

Yellow

Target dates and/or deliverables are at risk, but a resourced recovery work plan has been developed to achieve

program targets, and has been approved by the appropriate Management Team

None

Green

Target dates and deliverables are on track and meeting objectives.

INTERNAL VALIDATION FOR TOOLS

Validation Plan Numr

Key contact/ Phone/ e-mail

Date (Orig.)

Date (Rev.)

Številka plana nadzora

Ključna kontaktna oseba/ telefon/ e-mail

Datum izdaje (Orig.)

Datum zaporedne izdaje (Rev.)

Part Number/Latest Change Level

Core Team

Customer Engineering Approval/Date (If Req'd.)

Številka dela/Raven tehnične spremembe

Člani tima

Odobritev razvoja kupca/Datum (če je zahtevano)

Customer approval

Part Name/Description

Supplier/Plant Approval/Date

Customer Quality Approval/Date (If Req'd.)

Naziv/Opis dela

Odobritev dobavitelja/Lokacija/Datum

Odobritev kontrole kakovosti kupca/ datum (če je zahteva)

Supplier/Plant

Supplier Code

Other Approval/Date (If Req'd.)

Dobavitelj- proiz. lokacija

Šifra dobavitelja

Ostale odobritve/Datum (če je zahtevano)

Nr. of validation step (Št. Koraka)

Tool VALIDATION STEPS (KORAKI VALIDACIJE)

Tool Completeness (Kompletnost orodja)

Drawing number and version (Št. Risbe in verzija)

Number of tool parts (Št. delov orodja)

Date of Tool Completion (Datum izdelave orodja)

Tool Completness Documentation (Dokumentacija kompletnosti orodja)

Certificates, Confrimation forms, Other documentation (Certifikati, Potrdila in Ostala dokumentacija)

Technical Remarks and Comments (Tehnične Opazke in Komentarji)

Trial Die Casting (Preizkusno litje)

Number of castings (Št. Litij)

Material (Material)

Material Supplier (Dobavitelj materiala)

Producer (Izvajalec)

Machine (Stroj)

No. of samples

(Št. vzorcev)

Date of manufacturing (Datum vzorčne serije)

Parameters (Parametri)

Comments (Komentarji)

Measurements (Meritve)

Number of measurements (Št. Meritev)

Function (Funkcija)

Size (Velikost)

Frequency (Frekvenca)

Product- process

specification- tolerance (Proizvod- proces

Specifikacije- tolerance)

Method of measurement (Metoda merjenja)

CC and SC (Kritične mere)

Results (Rezultati)

Date of measurement (Datum meritve)

Controler Name (Ime Kontrolorja)

MR - Measurement documentation (MR - Dokumentacija meritev)

Measurement Protocol (Merilni protokol)

MR acceptable (MR sprejemljiv)

MR validation document (MR dokument validacije)

Nr. Of measured parts (Št. Pomerjenih kosov)

Number of gold samples (Št. zlatih vzorcev)

PPAP documentation (PPAP dokumentacije)

Identificaiton of additional measurements and QA (Identifikacija drugih meritev in QA)

Comments (Komentarji)

Submitting samples with measuring protocol (Posredovanje vzorcev z merilnim protokolom)

Measurement documentation sent to Customer (Merilna dokumentacija poslana kupcu)

PPAP sent to Customer (PPAP poslan kupcu)

PSW sent to Customer (PSW poslan kupcu)

PPAP documentation change (PPAP dokumenti sprememb)

MR documentation change(PSW dokumentacija sprememb)

Date of submittion (Datum posredovanja)

Number of samples (Št. vzorcev)

Sent to customer for inspection Y / N (Poslano kupcu za pregled)

Comments (Komentarji)

Customer Confirmation (Potrditev s strani kupca)

PSW confirmation(PSW potrditev)

Corrections of PPAP, MR (Korekcije PPAP, MR)

Implementation of PPAP, MR (Implementacija PPAP, MR)

Date of Confirmation (Datum potrditve)

Date of Implementation (Datum implementacije)

Comments (Komentarji)

First Series Manufacturing (Proizvodnja prve serije)

Date of manufacturing (Datum vzorčne serije)

No. of products

(Št. vzorcev)

Ability to process CP / CPK (Sposobnost procesa CP /CPK)

Control according to QP (Kontrola po QP)

Controler Name (Ime Kontrolorja)

Comments (Komentarji)

This is only an example of internal validation of tool.

First 15 rows represent the HEADER of Form. It includes: validation plan number, part number, last change, part name, description, supplier, plant, supplier code, key contact people, dates and approval dates, customer quality approval, customer engineering approval, core team.

1 STEP - TOOL COMPLETNESS: Step includes tool documentation, check list for all tool parts, validations if tool was completed. It also adds an attachements of documents such as drawings, forms, certificates, validations..etc.

2 STEP - TRIAL DIE CASTING: We start the function test if tool works correctly. We prepeare the tool by steps of assembly and parameters. We start the trial die casting of small quantities 10 - 100 pieces. We record all parameters and figures of trial die casting. We prepeare samples for approval process, measurments, x-rays, spectroanalysis,..etc.

3 STEP - MEASUREMENTS: We make the measurments, x-ray, spectoanalysis and create reports.

4 STEP - MEASUREMENT PROTOCOL: We check the measurement results and completed PPAP documentation.

5 STEP - SUBMITTING SAMPLES WITH MEASUREMENT PROTOCOL: We sent the PPAP documentation, MR results and samples to customer.

6 STEP - CUSTOMER CONFIRMATION: PSW confirmation from customer.

7 STEP - FIRST SERIES MANUFACTURING: This step is taken only when the PSW has been confirmed, all documentation has been successfully approved and first samples have been accepted by customer. In case of manufacturing we fill the date, number of products, approve the Cp/Cpk capability of process, controling the samples according to QP.

27.1.2017, Janez Jurančič

Standard Measurement

Datum merjenja

Merilna oprema

Measurment equipment

Dimenzija

Dimension

Izmerjena vrednost

Measured value

CTQ Y / N ?

Pregled in komentarji

Rewiew & Comments

Vzorec 1

Sample 1

Vzorec 2

Sample 2

Vzorec 3

Sample 3

Vzorec 4

Sample 4

Vzorec 5

Sample 5

Dobavitelj / Supplier

Kupec / Customer

Pregled /Rewiew

Komentar / Comments

Pregled /Rewiew

Komentar / Comments

MSA

Pregled in komentarji

Rewiew & Comments

Critical to Quality?

Datum merjenja

Merilna oprema

Measurment equipment

Dimenzija

Dimension

Toleranca

Tolerance

Izmerjena vrednost

Measured value

Dobavitelj / Supplier

Kupec / Customer

Zgornja tolerančna meja

Upper dimension

Spodnja tolerančna meja

Lower dimension

Vzorec 1

Sample 1

Pregled /Rewiew

Komentar / Comments

Pregled /Rewiew

Komentar / Comments

Simboli / Symbols:
Simboli / Symbols:

CORRECTIVE ACTION REPORT

Supplier Name:

Attention:

Phone:

Supplier no:

Report #:

1. Problem Description - Include facts (i.e., where discovered, by whom, when), specifications, references and attachments

Customer:

Purchase Order #:

Customer Location:

Customer Part #:

Date Issued:

Organization Part #:

Issuer of report:

Part Name:

Issuer Phone:

Quantity Shipped:

Issuer email:

Quantity Rejected:

Pieces were defected during die-casting process, which resulted that diameters are out of specifications. Diameter is out of specification by + 0,1 mm to + 0,2 mm above maximum tolerance of 5,20 mm.

(Photo/Sketch)

2. Team Roster

Name:

Organization:

Title:

Phone:

E-Mail:

3. Containment Action - Interim action to immediately isolate the effect of the problem

Task Description:

Assigned to:

Due Date:

Effective Date:

Results Achieved:

Quarantine stock / stop delivery.

Sort stock.

4. Root Cause Analysis - Underlying reasons why the problem OCCURED, why it was not DETECTED and why the related process, from a systemic viewpoint, ALLOWED the nonconformance to occur.

4a. Identification of Root Causes and Priority Ranking

(0 = No Impact, 1 = Low, 2 = Medium, 3 = High)

Rank (0 - 3)

Cause Categories:

Description

People

Methods/Procedure

Equipment

Material

Environment

Measurement

4b. Five-Why Analysis of Root Causes - Answer why the problem occurred AND why it escaped system controls

Cause:

Why?

5. Corrective Action - Steps taken to eliminate root cause(s).

The solution to this problem includes a detection mechanism or error-proofing device to prevent recurrence: ( ) Yes ( ) No

Task Description:

Assigned to:

Due Date:

Effective Date:

Results Achieved:

6a. Preventive Action - Steps taken to modify systems and procedures to prevent recurrence of a similar kind elsewhere

Task Description:

Assigned to:

Due Date:

Results Achieved:

6b. Read-Across - Steps taken to implement or share preventive action within other sites of the business unit or corporation.

Task Description:

Assigned to:

Due Date:

Results Achieved:

7. Verification - Identify methods to verify completion and effectiveness of actions taken

Verify the implementation and changes to: (X) Policies/Procedures (X) Work Instructions (X) FMEA (X) Control Plans ( ) N/A

Method:

Assigned to:

Due Date:

Results:

8a. Supplier Management Review - Endorsement and support by the organization responsible for correction

Date

Phone:

Originator's Name:

Sign:

Approved:

E-Mail:

Date

Phone:

Top Management:

Sign:

Approved:

E-Mail:

8b. Final Closure - Parker responsible for closing Corrective Action Report

Quality Management

Date

Phone:

Representative:

Sign:

Closed:

E-Mail:

Pareto Analysis

SUM OF PRODUCTS

Failure Type /Name

Nr. Failures

Procentage

Sum %

Nr. Produced

SUM

#DIV/0!

LibreOffice/6.0.7.3$Linux_X86_64 LibreOffice_project/00m0$Build-3 %

Pareto diagram - events

Nr. Events

DATE:

Failure Accumulation Chart

REVISION:

PREPEARED:

Gorenje

Assy Plant:

Time Period

Assy Line:

Test Character:

Part Description:

Test Frequency:

Department:

Total

LibreOffice/6.0.7.3$Linux_X86_64 LibreOffice_project/00m0$Build-3 % %

;

#DIV/0!

# of noncon. Parts

# of tested Parts

ppm:

#DIV/0!

5000

LibreOffice/6.0.7.3$Linux_X86_64 LibreOffice_project/00m0$Build-3

;

5000

Control Limit (ppm)

5000












								3
								10


























































																								Op A	13.95	13.95	13.96	13.99	13.98	13.96	13.94	13.92	13.9	13.95	13.95	13.94	13.91	13.92	13.91	13.98	13.94	13.95	13.95	13.95	13.96	13.96	13.96	13.95	13.97	13.97	13.96	13.97	13.96	13.96	13.9506666666667

												13.95	13.95	13.96	13.97	13.97	13.98	13.96	13.96	13.98	13.9644444444444









																					13.9533333333333	13.9733333333333	13.9666666666667























13.9533333333333	NaN	NaN	0.0100000000000016	NaN	NaN	13.9558888888889	0.0176666666666669	13.9739618888889	13.9378158888889	0.0454916666666672


											30

Op A

NaN












								3
								10


























































																								Op A	13.95	13.95	13.96	13.99	13.98	13.96	13.94	13.92	13.9	13.95	13.95	13.94	13.91	13.92	13.91	13.98	13.94	13.95	13.95	13.95	13.96	13.96	13.96	13.95	13.97	13.97	13.96	13.97	13.96	13.96	13.9506666666667

												13.95	13.95	13.96	13.97	13.97	13.98	13.96	13.96	13.98	13.9644444444444









																					13.9533333333333	13.9733333333333	13.9666666666667























13.9533333333333	NaN	NaN	0.0100000000000016	NaN	NaN	13.9558888888889	0.0176666666666669	13.9739618888889	13.9378158888889	0.0454916666666672


											30